Compositions and methods for improved abrasion resistance of polymeric components

ABSTRACT

Described herein are component compositions comprising a blend of a polymer resin together with silica glass beads. In certain embodiments, the components demonstrate improved abrasion resistance as do the industrial fabrics produced that comprise at least one component of the instant disclosure.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. patent application Ser. No.15/157,780 filed May 18, 2016, which claims the benefit of priority ofU.S. Provisional Application Ser. No. 62/237,300 filed Oct. 5, 2015. Theforegoing applications are incorporated by reference herein in theirentireties.

FIELD OF THE DISCLOSURE

This application and the disclosures described herein generally discussand relate to polymeric compositions comprising silica particles. Moreparticularly, the invention relates to a polymer resin composition usedin the manufacture of components for use in industrial fabrics and beltsmade from mixing a polymer resin with a silica particle additive toimprove the abrasion resistance of the industrial fabric or beltcomprising the component.

BACKGROUND OF THE DISCLOSURE

An industrial fabric or belt is an endless structure in the form of acontinuous loop such as a forming fabric, press fabric, dryer fabric orprocess belt (e.g., shoe press belt, transfer belt, calendar belt), reelbelt, a structure used as an impression fabric, through air dryer(“TAD”) fabric used in the production of tissue and towel (togetherknown as “paper machine clothing” or “PMC”). Other industrial fabricsinclude: corrugator belts for producing corrugated boxboard, fabrics andbelts and sleeves used in the production of nonwovens by processes suchas melt-blowing, spun bond, hydroentangling, or air laid; a fabric usedin a sludge filter or other wet filtration processes; or a fabric usedin textile finishing processes such as sanforizing; belts used in hidetanning; and other conveyor belts such as those used in food processing.

While the discussion here is for the papermaking process in general, theapplication of the present disclosure is not considered limited thereto.

During the papermaking process, a cellulosic fibrous web is formed bydepositing a fibrous slurry, that is, an aqueous dispersion of cellulosefibers, onto a moving forming fabric in a forming section of a papermachine. A large amount of water is drained from the slurry through theforming fabric, leaving the cellulosic fibrous web on the surface of theforming fabric.

The newly formed cellulosic fibrous web proceeds from the formingsection to a press section, which includes a series of press nips. Thecellulosic fibrous web passes through the press nips supported by apress fabric, or, as is often the case, between two such press fabrics.In the press nips, the cellulosic fibrous web is subjected tocompressive forces which squeeze water therefrom, and which adhere thecellulosic fibers in the web to one another to turn the cellulosicfibrous web into a paper sheet. The water is accepted by the pressfabric or fabrics and, ideally, does not return to the paper sheet.

The paper sheet finally proceeds to a dryer section, which includes atleast one series of rotatable dryer drums or cylinders, which areinternally heated by steam. The newly formed paper sheet is directed ina serpentine path sequentially around each in the series of drums by adryer fabric, which holds the paper sheet closely against the surfacesof the drums. The heated drums reduce the remaining water content of thepaper sheet to a desirable level through evaporation.

It should be appreciated that the forming, press and dryer fabrics alltake the form of endless loops on the paper machine and function in themanner of conveyors. It should further be appreciated that papermanufacture is a continuous process which proceeds at considerablespeeds. That is to say, the fibrous slurry is continuously depositedonto the forming fabric in the forming section, while a newlymanufactured paper sheet is continuously wound onto rolls after it exitsfrom the dryer section.

In the production of tissue or towel, forming and press fabrics providethe same function as in paper making above. There may also be otherfabrics such as impression fabrics or TAD fabrics, as well as reelbelts.

Base fabrics, which form an important portion of the above discussedfabrics, take many different forms. For example, they may be woveneither endlessly or flat woven and subsequently rendered into endlessform with a woven seam using one or more layers of machine direction(“MD”) and cross-machine direction (“CD”) yarns. Further, the woven basefabrics may be laminated by placing one base fabric within the endlessloop formed by another, and joining or laminating together by variousmeans known to those skilled in the art such as by needling a staplefiber batt through both base fabrics to join them to one another.

Different polymeric materials may be used in the formation of MD/CDyarns and if present, the batt fibers that form these fabrics. Oneexample of a polymeric resin that may be used for this purpose ispolyester. Because these fabrics are exposed to harsh environments, itis essential that the material used to form these yarns and fibersexhibit good abrasion-resistant properties. While pure (100%) materialused for a yarn or fiber, for example, polyester as a forming fabricyarn, has excellent required yarn modulus, it has relatively poorabrasion resistance. While attempts to improve these shortcomings havebeen made, none have shown the required level of improvement.

Other structural components such as foils or films, can be used as alayer in a structure for the uses aforementioned. Such films comprisepolymers such as, but not limited to, polyester or polyurethane.

Lastly, coatings such as used to manufacture shoe press belts, calendarbelts, transfer belts, certain tissue/towel impression fabrics, andseveral of the engineered fabrics also have this requirement ofanti-contamination or easier removal of contaminants. The coatings maycomprise polyurethane or other polymers.

Products comprising various amounts of inorganic compounds and/ormineral fillers have been known. For example, U.S. Pat. No. 6,323,271pertains to a polyester resin containing silica beads used in beveragecontainers to reduce the surface coefficient of friction. U.S. Pat. Nos.5,278,221, 5,278,205, 5,137,939, and 5,132,356 likewise pertain to filmsof polyester containing glass spheres to reduce the dynamic coefficientof friction of the film and the addition of fumed silica to improve thestatic coefficient of friction of the film. U.S. Pat. No. 3,230,184relates to a PET resin for molding with a fibrous material and hollowdiscrete spheres of silicate-based glass. Further, European Pat. No.EP648,802 relates to polyester film with polyester polymer containingprecipitated silica particles and calcined clay. British Pat. No.GB954024A discloses the production of improved polyester filaments withsome form of silica particles less than 20 microns in diameter. U.S.Pat. No. 3,486,266 appears to disclose a sheath core material withplasticized polyvinyl chloride having microscopic glass beads dispersedtherein. U.S. Pat. No. 5,207,959 discloses fumed silica with a particlesize of between 5 and 15 nm mixed into a molten polymer. Further, U.S.Pat. No. 5,132,356 relates to a polyester film containing small glassspheres and fumed silica. In that disclosure, the polyester filmcontains glass spheres having an average particle size of 2-3 micronsand a particle distribution of 99.9% below about 8 microns. U.S. Pat.No. 6,544,644 is directed toward abrasion resistant spun articles anddiscloses threads, fibers, or filaments containing 0.05-20 wt %nanoparticles dispersed in the resin. U.S. Pat. No. 6,838,173 pertainsto a polyester fiber and production method of polyester composition. Inthat disclosure, the polyester fiber comprises silica-based inorganicparticles (1-20 wt %) with an average particle diameter of 0.01-10microns. U.S. Pat. No. 8,691,906 discloses a method for producingmonofilament fibers comprising an aliphatic-aromatic polyester, ahydrolysis stabilizer, and spherical particles of oxides of silicon, ofaluminum, and/or of titanium having an average particle diameter of notmore than 100 nm. U.S. Pat. No. 8,383,716 relates to polyesternanocomposites made of polyester and silica nanoparticles therein, wherethe surface of the nanoparticles is modified by3-[(propyleneoxycarbonylamido)propyl]-trialkyloxysilane. Finally, U.S.Pat. No. 8,883,917 discloses nylon polymers having a low coefficient offriction and method for preparation of a polyamide-based compositioncomprising particulate silica substantially uniformly dispersed into apolyamide matrix.

When a fabric structure is used as paper machine clothing, thecomponents (for example, monofilaments in a woven structure) aregenerally exposed to harmful, abrasive environments that cause wear andtear to the fabrics. A component demonstrating abrasion resistantproperties is therefore needed.

SUMMARY OF THE DISCLOSURE

An object of this disclosure is to create a polymeric composition usedto form a component for use in an industrial fabric with improvedabrasion-resistant properties.

The present disclosure is directed to compositions comprising at leastone polymeric resin and at least one silica particle. The compositionsmay be extruded or spun into fibers, yarns, films, foils, nettings,meshes, structured deposits, and other extruded or spun elements likerings and spiral coils. The compositions may be used as wear surfaces ofindustrial fabrics such as paper machine clothing (PMC) or engineeredfabrics, including use as binder yarns in multilayer woven fabrics. Ithas been found that the addition of certain micron-sized silicaparticles to a polymer melt during the extrusion or spinning processyields a component with improved abrasion resistance.

“Components” include fibers, filament yarns, films, foils, tapes,netting (mesh), rings, spiral link coils or other extruded or spunelements, a structured deposit in a desired pattern, or a coating(either the deposit or coating can be continuous on a surface, ordiscontinuous in a desired pattern (for example rectangles), or side byside continuous or discontinuous MD or CD strips wherein the edges ofthe adjacent strips are not in contact with each other, e.g., there is a“space” in between adjacent strips). The strips can also be at an angleto the MD, and can be curved, zigzagged or sinusoidal in shape. Incertain embodiments, an advantage of the present disclosure is toimprove the abrasion-resistant properties of the component.

It is an object of the present disclosure to provide a componentcomposition comprising at least one polymer resin and at least onesilica particle, which is suitable for the production of fibers,filaments, films, foils, tapes, netting, meshes, rings or other extrudedor spun elements, a structured deposit in a desired pattern, or acoating exhibiting improved abrasion resistance-compared to componentsof pure 100% polymer resin or other combinations of resin and additives.

It is another object of the present disclosure to provide an industrialfabric or belt with improved abrasion-resistant properties where thatfabric or belt is produced using a component comprising at least onepolyester resin, such as for example: polyethylene terephthalate (PET),polyethylene naphthalate (PEN), polybutylene terephthalate (PBT),polybutylene naphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), copolymers orblends of polyester; or a polyamide, such as, for example PA 6; PA 6,6;PA 6,12; PA 6,10; PA 4,6; PA 10; PA 11; PA 12; or MXD6; or, aromaticpolyamides (polyaramids); or, copolymers or blends of polyamides; or,polyphenyl sulfide (PPS) or blends thereof; or, polyether ether ketone(PEEK) or blends thereof; or, polyether ketone (PEK) or blends thereof;or polyurethane or blends thereof. “Blends thereof” as used herein meansthat the resin named can be blended with another resin, for example,such as a polyester can be blended with a urethane, or two polyesters ortwo polyamides can be blended together.

The polymer composition according to the present disclosure is suitablefor the production of components such as fibers and filament yarns. Morespecifically, the polymer resin composition is suitable formanufacturing of yarns, fibers, films, foils, tapes, netting, meshes,rings or other extruded or spun elements, a structured deposit in adesired pattern, or a coating made from a blend of at least one polymerresin, at least one type of silica particles, and optionally otheradditives that can be used in industrial fabrics, and a method ofmanufacturing the same.

In certain embodiments, a composition suitable for the production of theaforementioned components exhibiting the above discussed properties isobtained by blending and extruding at least one type of silica particleswith at least one polymer resin.

As described herein, the invention relates to a resin componentcomposition comprising at least one polymer resin and at least one typeof silica glass bead. In certain embodiments, the silica glass beadcomprises a metal oxide. In further embodiments, the silica glass beadis selected from A-glass and E-glass beads. In some embodiments, thecomposition comprises about 1% to about 4% by weight silica glass beads.In some embodiments, the silica glass beads are between 0.01-10 micronsin average particle size diameter. In certain embodiments, the silicaglass beads are between 0.1-10 microns in average particle sizediameter. In other embodiments, the silica glass beads are between 1-10microns in average particle size diameter.

In some embodiments, the composition comprises about 4% to about 98% byweight of a polymer resin. In certain embodiments, the compositionfurther comprises about 1% to about 4% by weight silica glass beads. Infurther embodiments, the composition comprises about 0.5% to about 5% byweight of a siloxane content additive. In a particular embodiment, thesiloxane content additive comprises polydimethylsiloxane (PDMS). Incertain embodiments, about 1% to about 5% of said composition by weightcomprises a siloxane content additive. In some embodiments, the silicaglass beads are substantially round or spherical. In some embodiments,the silica glass beads are between 0.01-10 microns in average particlesize diameter. In certain embodiments, the silica glass beads arebetween 0.1-10 microns in average particle size diameter. In otherembodiments, the silica glass beads are between 1-10 microns in averageparticle size diameter.

In some embodiments, the polymer resin of the composition comprises atleast one polymer selected from the group consisting of: polyethylenenaphthalate (PEN), polyethylene terephthalate (PET), polybutylenenaphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), polybutyleneterephthalate (PBT), polyamide (PA 6; PA 6,6; PA 6,12; PA 6,10; PA 4,6;PA 10; PA 11; PA 12; MXD6, and aromatic derivatives thereof), polyetherether ketone (PEEK), polyether ketone (PEK) and poly(p-phenylenesulfide) (PPS/RYTON®), polyurethane, polysiloxane, and copolymersthereof. In certain embodiments, the polymer resin comprises at leastone polyester selected from the group consisting of: polyethylenenaphthalate (PEN), polyethylene terephthalate (PET), polybutylenenaphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), andpolybutylene terephthalate (PBT).

In some embodiments, the composition comprises at least two polymerresins. In further embodiments, the composition comprises two or morepolymers selected from the group consisting of polyethylene naphthalate(PEN), polyethylene terephthalate (PET), polybutylene naphthalate (PBN),polytrimethylene naphthalate (PTN), poly(cyclohexylene dimethyleneterephthalate) acid (PCTA), polybutylene terephthalate (PBT), polyamide(PA 6; PA 6,6; PA 6,12; PA 6,10; PA 4,6; PA 10; PA 11; PA 12; MXD6, andaromatic derivatives thereof), polyether ether ketone (PEEK), polyetherketone (PEK) and poly(p-phenylene sulfide) (PPS/RYTON®), polyurethane,polysiloxane, and copolymers thereof.

In some embodiments, the polymer resin of the composition comprises PET.

In certain embodiments, the composition comprises A-glass beads. Inother embodiments, the composition comprises E-glass beads. In yet otherembodiments, the composition comprises both A-glass and E-glass beads.In certain embodiments, the composition further comprises the siloxanecontent additive PDMS.

In some embodiments, the composition comprises about 4% to about 98% byweight of a polymer resin. In certain embodiments, the compositioncomprises one polymer resin in an amount of about 20% to about 98% ofsaid composition by weight. In certain embodiments, the compositioncomprises at least two polymer resins. In further embodiments, about 20%to about 98% of the composition by weight comprises two or more polymerresins.

In some embodiments, the composition comprises about 4% to about 98% byweight of a polymer resin and about 1% to about 4% by weight silicaglass beads. In certain embodiments, about 20% to about 98% of thecomposition by weight comprises a polymer resin. In further embodiments,about 20% to about 98% of the composition by weight comprises two ormore polymer resins.

In some embodiments, the composition comprises about 4% to about 98% byweight of a polymer resin and about 1% to about 4% by weight silicaglass beads, wherein the at least one polymer resin is PET and thesilica glass beads are A-glass beads. In other embodiments, the at leastone polymer resin is PET and the silica glass beads are E-glass beads.In yet other embodiments, the at least one polymer resin is PET and thesilica glass beads are both A-glass and E-glass beads.

In a particular embodiment, the composition comprises (a) 89% by weightPET; (b) 6% by weight PBT; (c) 2% by weight of a siloxane additive; (d)1% by weight carbodiimide; and (e) 2% by weight silica glass beads.

In some embodiments, the composition of the invention comprises one ormore additives selected from the group consisting of: stabilizers,compatibilizers, hydrolysis or oxidation-resistant additives, dyes, andpigments.

The invention further relates to a monofilament yarn comprising a resincomponent composition comprising at least one polymer resin and at leastone type of silica glass bead, wherein about 4% to about 98% of thecomposition by weight comprises a polymer resin and about 1% to about 4%of the composition by weight comprises silica glass beads, optionallywherein the resin component composition comprises about 0.5% to about 5%by weight of a siloxane content additive. In certain embodiments, thewater contact angle on the monofilament yarn surface is greater than 74degrees. In some embodiments, the monofilament yarn has a round ornon-round cross-section. In certain embodiments, the abrasion resistanceof the monofilament yarn is improved at least 5% compared to saidmonofilament yarn made without silica glass beads. In some embodiments,the abrasion resistance of the monofilament yarn is improved at least10% compared to said monofilament yarn made without silica glass beads.In other embodiments, the abrasion resistance of the monofilament yarnis improved at least 15% compared to said monofilament yarn made withoutsilica glass beads. In yet other embodiments, the abrasion resistance ofthe monofilament yarn is improved at least 20% compared to pure polymerresin monofilament yarn.

In some embodiments, the instant invention relates to a method ofmanufacturing a resin component composition comprising a polymer resin,silica glass beads, wherein said silica glass beads are addedsimultaneously to said polymer resin, which is then extruded or spun. Inother embodiments, the resin component composition manufacturing methodfurther comprises a siloxane additive, wherein a siloxane additive andthe silica glass beads are added simultaneously to the polymer resin,which is then extruded or spun.

In some embodiments, the method of manufacturing the compositioncomprises one or more polymers selected from the group consisting of:polyethylene naphthalate (PEN), polyethylene terephthalate (PET),polybutylene naphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), polybutyleneterephthalate (PBT), polyamide (PA 6, PA 6,6, PA 6,12, PA 6,10, PA 4,6,PA 10, PA 11, PA 12; MXD6, and aromatic derivatives thereof), polyetherether ketone (PEEK), polyether ketone (PEK), poly(p-phenylene sulfide)(PPS/RYTON®), polyurethane, polysiloxane, and copolymers thereof.

In certain embodiments, the method of manufacturing the compositioncomprises two or more polymers selected from the group consisting of:polyethylene naphthalate (PEN), polyethylene terephthalate (PET),polybutylene naphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), andpolybutylene terephthalate (PBT). In other embodiments, the method ofmanufacturing the composition comprises at least two polymer resins,wherein the silica glass beads are added simultaneously to the polymerresins, which are then extruded or spun. In further embodiments, themethod of manufacturing the resin component composition furthercomprises a silicone additive, wherein a siloxane additive and thesilica glass beads are added simultaneously to the polymer resins, whichare then extruded or spun. In some embodiments, the method ofmanufacturing the composition comprises two or more polymers selectedfrom the group consisting of: polyethylene naphthalate (PEN),polyethylene terephthalate (PET), polybutylene naphthalate (PBN),polytrimethylene naphthalate (PTN), poly(cyclohexylene dimethyleneterephthalate) acid (PCTA), polybutylene terephthalate (PBT), polyamide(PA 6, PA 6,6, PA 6,12, PA 6,10, PA 4,6, PA 10, PA 11, PA 12; MXD6, andaromatic derivatives thereof), polyether ether ketone (PEEK), polyetherketone (PEK), poly(p-phenylene sulfide) (PPS/RYTON®), polyurethane,polysiloxane, and copolymers thereof. In further embodiments, the methodcomprises two or more polymers selected from the group consisting of:polyethylene naphthalate (PEN), polyethylene terephthalate (PET),polybutylene naphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), andpolybutylene terephthalate (PBT).

In some embodiments, the instant invention relates to a method ofmanufacturing a resin component composition comprising a polymer resin,silica glass beads, wherein said silica glass beads are addedsimultaneously to said polymer resin, which is then extruded or spun,wherein the composition comprises one or more additives selected fromthe group consisting of: stabilizers, compatibilizers, hydrolysis oroxidation-resistant additives, dyes, and pigments. In other embodiments,the composition is extruded or spun into a component selected from thegroup consisting of fiber, yarn, rings, films, foil, tape, mesh, spirallink coil and netting; or is a structured deposit or coating.

In some embodiments, the instant invention pertains to a component of anindustrial fabric, wherein the component comprises a resin componentcomposition comprising at least one polymer resin and at least one typeof silica glass bead, wherein about 4% to about 98% of the compositionby weight comprises a polymer resin and about 1% to about 4% of thecomposition by weight comprises silica glass beads, optionally whereinthe resin component composition comprises about 0.5% to about 5% byweight of a siloxane content additive. In certain embodiments, thecomponent is selected from the group consisting of yarn, fiber, film,foil, tape, netting, mesh, ring, spiral link coil, structured deposit,and coating. In certain embodiments, the industrial fabric is selectedfrom the group consisting of PMC forming, press, and dryer fabrics,process belts, impression fabrics; TAD fabrics; eTAD fabrics; and ATMOSmachine fabrics. In some embodiments, the industrial fabric is selectedfrom the group consisting of engineered fabrics, sleeves and belts usedin the production of nonwoven fabrics by processes such as air laid,melt blowing, spunbonding, and hydroentangling fabrics used in a sludgefilter and other wet filtration processes; conveyor belts; andcorrugator belts. In some embodiments, the industrial fabric is selectedfrom the group consisting of spiral coil links, their pintles andstaffer yarns; fabrics and belts used in textile finishing processes;belts and fabrics used to produce building products; tannery belts, andtannery sleeves. In some embodiments, the fabric component is selectedfrom the group consisting of fabrics woven from yarns in the MD and CD,nonwoven fabric layers of MD or CD yarn arrays, fabrics made from spirallinks, or the spiral links themselves, mesh, netting, rings, foils,films, and other extruded elements.

In some embodiments, the instant invention relates to a mesh, netting,ring, film, fiber, or paper machine clothing comprising a resincomponent composition comprising at least one polymer resin and at leastone type of silica glass bead, wherein about 4% to about 98% of thecomposition by weight comprises a polymer resin and about 1% to about 4%of the composition by weight comprises silica glass beads, optionallywherein the resin component composition comprises about 0.5% to about 5%by weight of a siloxane content additive. In certain embodiments, thefiber is suitable for use in the batt portion of an industrial fabric.

In yet other embodiments, the instant invention pertains to a reel belt,TAD, eTAD, ATMOS, DNT, PMC forming, press, and dryer fabric; processbelts, impression fabric, belt filter, pulp washer cover, or belt toproduce a building product comprising a resin component compositioncomprising at least one polymer resin and at least one type of silicaglass bead, wherein about 4% to about 98% of the composition by weightcomprises a polymer resin and about 1% to about 4% of the composition byweight comprises silica glass beads, optionally wherein the resincomponent composition comprises about 0.5% to about 5% by weight of asiloxane content additive.

In some embodiments, the instant invention relates to an engineeredfabric; air laid, spun bond, melt spun, or hydroentangled fabriccomprising a resin component composition comprising at least one polymerresin and at least one type of silica glass bead, wherein about 4% toabout 98% of the composition by weight comprises a polymer resin andabout 1% to about 4% of the composition by weight comprises silica glassbeads, optionally wherein the resin component composition comprisesabout 0.5% to about 5% by weight of a siloxane content additive.

In other embodiments, the instant invention pertains to a corrugatorbelt, comprising a resin component composition comprising at least onepolymer resin and at least one type of silica glass bead, wherein about4% to about 98% of the composition by weight comprises a polymer resinand about 1% to about 4% of the composition by weight comprises silicaglass beads, optionally wherein the resin component compositioncomprises about 0.5% to about 5% by weight of a siloxane contentadditive.

In some embodiments, the instant invention relates to a batt portion ofpress fabric or corrugator belt fabric comprising a resin componentcomposition comprising at least one polymer resin and at least one typeof silica glass bead, wherein about 4% to about 98% of the compositionby weight comprises a polymer resin and about 1% to about 4% of thecomposition by weight comprises silica glass beads, optionally whereinthe resin component composition comprises about 0.5% to about 5% byweight of a siloxane content additive.

In some embodiments, the instant invention relates to a stuffer yarn orpintle comprising a resin component composition comprising at least onepolymer resin and at least one type of silica glass bead, wherein about4% to about 98% of the composition by weight comprises a polymer resinand about 1% to about 4% of the composition by weight comprises silicaglass beads, optionally wherein the resin component compositioncomprises about 0.5% to about 5% by weight of a siloxane contentadditive.

Terms “comprising” and “comprises” in this disclosure can mean“including” and “includes” or can have the meaning commonly given to theterm “comprising” or “comprises” in U.S. Patent Law. Terms “consistingessentially of” or “consists essentially of” if used in the claims havethe meaning ascribed to them in U.S. Patent Law. Other aspects of thedisclosure are described in or are obvious from (and within the ambit ofthe disclosure) the following disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the disclosure, are incorporated in and constitute apart of this specification.

FIG. 1 is an Einlehner Abrasion graph comparing the depth of cut (mm) ofdifferent monofilaments-comprising 100% PET, the same PET with 3%silica, 2% silica, or 1% silica, respectively (each containing silicaA-glass beads); a PA6 control, and a PET control.

FIG. 2 depicts SEM cross section images (top—paper side view andbottom—cross section view) of an inventive monofilament with silicaE-glass beads embedded therein.

FIG. 3 depicts a stress versus strain plot of two monofilaments: theinventive 0.85 mm AIX-1391 (with silica E-glass beads) monofilamentversus a 0.85 mm HRS310 polyester (HR as used herein stands for“Hydrolysis Resistant”) monofilament.

FIG. 4 depicts a stress versus strain plot of the inventive 0.50 mmAIX-1390 (with silica A-glass beads) monofilament versus 0.50 mm S-70monofilament.

FIG. 5 depicts the results of hydrolysis testing of inventive yarnsincluding the inventive 0.85 mm PET monofilament with 2% silica A-glassbeads versus a 0.85 mm HR PET monofilament control.

FIG. 6 is a graph depicting the results of hydrolysis testing of theinventive monofilament yarns with standard yarns of the same diametersincluding PET yarns with 1.34% silica E-glass beads (3850-1), 2.0%silica E-glass beads (3850-50-2), 2.0% silica A-glass beads (3850-50-3),and 1.34% silica A-glass beads (3850-50-4), respectively, and a HR PETcontrol yarn.

FIG. 7 is an Einlehner Abrasion resistance graph depicting themonofilament yarn abrasion resistance of yarns comprising PET with 1.34%silica E-glass beads and 2% silica E-glass beads, respectively, and 100%PET and 100% PA6 control yarns, all of the same diameter.

FIG. 8 is a graph depicting the coefficient of friction percentdifference from a PET standard monofilament yarn compared to yarns ofthe same diameter including: S-67 (polyamide/polyurethane copolymer),PA6, the same PET containing 1.5% siloxane, NB3850-17-4 97.0% high IV(intrinsic viscosity) PET containing 3.0% siloxane, NB3850-17-3 98.0%high IV PET containing 2.0% siloxane, NB 3850-17-1 97.3% high IV PETcontaining 1.35% of the silica E-glass beads and 1.35% siloxane, PA6containing 2.0% siloxane and NB3850-17-2 96.0% high IV PET containing2.0% of the silica E-glass beads and 2.0% siloxane.

FIG. 9 depicts images showing the contact angle measurement of water ona 100% PET monofilament as 61-63 degrees, and on 10% PBTXXX062813C1 (asilica A-glass bead in PBT containing abrasion-resistant PETmonofilament) as 74.7 degrees.

FIG. 10 is a chart showing the abrasion resistance results of a fabricmade with the inventive abrasion resistant monofilaments (the “Hi LifePET fabric”) versus ones made with different standard monofilaments.These samples were all comprising 0.25 mm PET polymer yarns and a PA6control woven in the fabrics. Depicted is a chart of time to failure offabrics woven with shute monofilaments: 100% PET (Trial 1 2200029),Hi-Life PET (Trial 2 2200029), alternating PA6 and PET wear shutes(Trial 3 2210932), and Standard Forming (Q13 Standard).

FIG. 11 is a chart showing the percent loss of weight and caliper(thickness) of regular standard 0.85 mm PET versus Hi-Life PET, which isthe inventive abrasion resistant PET. These samples were of spiral linkfabrics made with the respective 0.85 mm yarn formed into spiral links.Depicted is an abrasion resistance comparison of 0.85 mm monofilamentfor spiral link fabrics. Lower weight and caliper loss is better for theinventive yarn. “Regular” is a spiral link fabric produced usingpolyester monofilament without glass beads.

FIG. 12 is a chart showing the time (in minutes) required to break(tear) four different fabrics with the same weave, yarn sizes, mesh andyarn counts comprising monofilament yarns comprising: a PET referencematerial (HCR 280), PET with 2.0% silica A-glass beads (AIX-1384), aHYTREL® reference material (AIX-1382), and HYTREL® with 2.0% silicaA-glass beads (AIX-1383). The monofilaments were all 0.50 mm round crosssections. HYTREL® is a COPE (copolyester elastomer). FIG. 12 shows tearstrength (measured in minutes to failure) of 4 different fabrics withthe same weave, mesh, count and yarn diameters, such as one with PETstandard yarns and the same size yarn of PET with 2% silica A-glassbeads, and one with HYTREL® resin yarns and one with the same HYTREL®and 2% silica A-glass beads.

FIG. 13 is an image showing a fabric woven with alternating monofilamentCD (cross direction) shute yarns (across the image) of composition S16180.50 mm S70 PET and 100% PA6 after 1 hour of external wear. The fabricshown is fabric with 0.50 mm PET shutes alternating with PA6 shutes. The“opaque” yarn is PET.

FIG. 14 is an image showing the wear of the fabric in FIG. 13, i.e.,S1618 0.50 mm S70 PET and 100% PA6, after 2 hours of external wear. Asshown in FIG. 14, yarns are worn completely through and broken.

FIG. 15 is an image showing a fabric woven the same as that of FIG. 13,but the S70 PET monofilament was replaced by one with a compositionS1618 0.50 mm AIX-1390 (the inventive yarn composition with A-glassbeads) and PA6 after 1 hour of external wear. The PET shute (CD) yarn ofFIG. 13 was replaced by the inventive yarn (same PET but with silicaglass beads). Opaque yarn is PET with glass beads.

FIG. 16 is an image showing the fabric of FIG. 15, i.e., S1618 0.50 mmAIX-1390 (the inventive yarn composition with A-glass beads) and PA6,after 2 hours of external wear. The improvement in wear (abrasion)resistance is clearly visually apparent compared especially to FIG. 14.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present disclosure combines one or more materials to a polymer resinin a synergistic manner, such that the properties (for example, breakstrength, elongation, etc.) of the components comprising the resin areat least maintained, and such that the combination of the one or moreadditive materials offers a synergistic positive effect of increasingthe component's abrasion-resistant properties. Generally, the additivematerials comprise silica particles. More specifically, the additivematerials comprise silica glass beads. The synergistic effect seen bycombining at least one type of silica glass bead additive with a polymerresin is a surprising and unexpected result of the instant disclosurewhen the component is present, for example, in an industrial fabric.

In the industrial fabric and belts aforementioned, the component of thepresent disclosure can be used to make extruded yarns for a wovenstructure, MD or CD yarn arrays, or to make the yarn used to manufacturespiral coil links, the pins or pintles used to link the coils together,or stuffer yarns (see, for example, U.S. Pat. No. 4,567,077); to make amesh or netting (see, for example, Johnson et al., U.S. Pat. No.4,427,734); to make rings (see, for example, Hansen et al., U.S. Pat.No. 6,918,998); or other extruded elements (see, for example, Hansen etal., U.S. Pat. No. 6,630,223); films or foils such as taught in U.S.Pat. Nos. 8,388,812; 8,728,280; 8,764,943; and 8,394,239; to make yarnsto be used in the pins or pintles to join the ends of on machineseamable fabrics together; to make fiber for use in structures such asthe batt portion of a press fabric or a corrugator belt; to make acontrolled structured deposition on the surface of a belt or fabric; orto coat (and/or impregnate) one or both surfaces of a belt or sleeve(e.g., sheet contact surface or machinery contact surface).

The component can be used in structures such as: PMC (forming fabrics,press fabrics, dryer fabrics, shoe press belts, or transfer belts), reelbelts, TAD fabrics, impression fabrics, Energy Efficient TechnologicallyAdvanced Drying (“eTAD”) fabrics, Advanced Tissue Molding Systems(“ATMOS”) fabrics; or engineered fabrics such as double nip thickeners(“DNT”) fabrics, belt filters, pulp washers, belts/fabrics/sleeves forthe production of nonwovens (for example, airlaid, spunbond, melt spun,hydroentangled), belts to produce building products (for example,oriented strand board (“OSB”)), corrugator belts, textile finishingbelts (for example, sanforizing belts), and tannery belts or sleeves.

In certain embodiments, the present disclosure improves the abrasionresistance properties, for example, of the component by blending atleast one polymer with at least one type of silica glass bead additiveduring or before the extrusion, spinning, deposition, or coatingprocess. The inventors have discovered a synergistic effect of thesesilica glass bead additives on components comprising polymer resins suchas polyester with industrial fabric applications such as a componentused in paper machine clothing. Because of the need for improvedabrasion resistance, while at least maintaining the other desiredproperties of the component, one aspect of the present disclosure is theproduction of monofilaments made from at least one polymer, such as apolyester resin, with at least one silica glass bead additive for use inyarns for industrial fabrics.

In certain embodiments, the present disclosure relates to a yarn orfiber having excellent abrasion-resistant properties, which comprises,at least one polymer, such as a polyester resin, and at least one typeof silica glass bead additive, combined to produce a monofilament yarncomposition. The present disclosure further relates to filaments, films,foils, tapes, netting, meshes, rings, spiral link coils or otherextruded or spun elements, a structured deposit in a desired pattern, ora coating (either the deposit or coating can be continuous on a surface,or discontinuous in a desired pattern (for example, rectangles), or sideby side continuous or discontinuous MD or CD strips wherein the edges ofthe adjacent strips are not in contact with each other, e.g., there is a“space” in between adjacent strips) produced by using this polymer resinand silica glass bead composition. The strips can also be at an angle tothe MD, and/or can be curved, zigzagged, or sinusoidal in shape.

In some embodiments, the present disclosure involves combining at thesame time one or more silica glass bead additives with one or morepolymeric materials, all of which is then extruded or spun. There may beadditional additives in the mixture, such as stabilizers,compatibilizers, hydrolysis or oxidation-resistant additives, dyes,and/or pigments. The polymeric material mixture is then extruded or spuninto fiber, yarn, rings, films, foils, meshes, nettings, or otherelements. The inventive material composition can also be used as astructured deposit or as a coating (either the deposit or coating can becontinuous on a surface, or discontinuous in a desired pattern (forexample, rectangles), or side by side continuous or discontinuous MD orCD strips wherein the edges of the adjacent strips are not in contactwith each other, e.g., there is a “space” in between adjacent strips) asa component of an industrial fabric or belt. The strips can also be atan angle to the MD, and/or can be curved, zigzagged, or sinusoidal inshape. The strips can be as narrow as 0.1 mm or as wide as severalmillimeters (measured in the CD if they are MD strips; measured in theMD if they are CD strips).

The structured deposit can be created by techniques such as dropletdeposition (see U.S. Pat. No. 7,005,044 for example), extrusion, rotaryscreen printing or the like.

For example, the industrial fabric may be a corrugator belt used on amachine producing corrugated boxboard. The surface of the belt, whichcan be a woven structure, a woven structure with needled in batt fiberon the sheet and/or machine contact sides, or a spiral link structure,which has deposited on the sheet contact surface a plurality of MDstrips of the inventive resin composition. The strips can be in the MD,at an angle to the MD, or in the CD. The strips can also be at an angleto the MD, and can be curved, zigzagged or sinusoidal in shape. Theadjacent strip edges are not contacting each other but there is a spaceto allow air and water vapor permeability through the belt.

The use of the improved abrasion resistant material makes the depositionmore durable, and therefore the functionality of the belt (assisting inpulling the corrugated board through the machine) lasts longer.

The industrial fabric may also be a transfer belt. It is important thatsuch belts exhibit excellent controlled sheet release and that thesurfaces remain contaminant free. Transfer belts are coated on bothsides (and sometimes impregnated as well) to achieve these properties.The coating can be applied separately to both sides, or from one sideand allowed to impregnate the structure, or a combination of both. Themachinery contact side should typically have sufficient roughness toprevent hydroplaning, and therefore not exhibit instability or poorguiding. The roughness can be achieved by grooving, for example. In aparticular embodiment, polyurethane is the preferred coating resin. Thefunctionality of the belt, especially sheet release, only lasts as longas the coating lasts, and its durability (abrasion resistant property)can be improved utilizing a composition comprising polyurethane and thesilica glass bead content material in the coating.

The silica glass bead additives may be mixed with any suitable polymer,such as one or more polyesters (e.g., PET, PBT, PEN, PCTA, etc.),polyamides (e.g., PA 6; PA 6,6; PA 6,12; PA 6,10; PA 4,6; PA 10; PA 11;PA 12 or polyaramid derivatives like NOMEX®), polyether ether ketone(PEEK), and/or polyether ketone (PEK), poly(p-phenylene sulfide) (PPS orRYTON®), or polyurethanes. The silica glass bead additives may also bemixed with two or more suitable polymers, such as two or more polyesters(e.g., PET, PBT, PEN, PCTA, etc.), polyamides (e.g., PA 6; PA 6,6; PA6,12; PA 6,10; PA 4,6; PA 10; PA 11; PA 12 or polyaramid derivativeslike NOMEX®), polyether ether ketone (PEEK), and/or polyether ketone(PEK), poly(p-phenylene sulfide) (PPS or RYTON®), polyurethanes, anycopolymers (e.g., HYTREL®) thereof, and any combination or blend thereof(e.g., PET/polyurethane, PET/polysiloxane, etc.). Other additives may bemixed in with the silica glass beads, including but not limited to,polysiloxanes (e.g., polydimethylsiloxane (PDMS), PDMS derivatives,polydiphenylsiloxane, cyclic polysiloxanes, aminoalkyl polysiloxanes,etc.).

The polymer composition may then be used as a component in industrialfabric structures such as PMC (forming fabrics, press fabrics, dryerfabrics, shoe press belts, or transfer belts), reel belts, TAD fabrics,impression fabrics, eTAD fabrics, and ATMOS fabrics; and engineeredfabrics such as DNT fabrics, belt filters, pulp washers,belts/fabrics/sleeves for the production of nonwovens (for example,airlaid, spunbond, melt spun, hydroentangled), belts to produce buildingproducts (for example, oriented strand board (“OSB”), corrugator belts,textile finishing belts (for example, sanforizing belts), and tannerybelts or sleeves).

The present disclosure, according to one embodiment, is a componentcomprising a blend of: (1) a polyester selected from a group includingbut not limited to, e.g., polyethylene naphthalate (PEN), polyethyleneterephthalate (PET), polybutylene naphthalate (PBN), polytrimethylenenaphthalate (PTN), polybutylene terephthalate (PBT), poly(cyclohexylenedimethylene terephthalate) acid (PCTA), or copolymers and blends ofpolyesters; and (2) a silica particle additive selected from a groupincluding but not limited to, e.g., E-glass silica beads, and A-glasssilica beads. The component composition optionally contains otheradditives and ingredients.

Optionally, stabilizers, such as a carbodiimide (e.g., Stabaxol® 1LF,PX-100, or PX-200), fillers, tensile modifiers, compatibilizers,hydrolysis or oxidation-resistant additives, dyes, and/or pigments orother additives may be used. In embodiments where the resin componentcomposition is used to produce a monofilament yarn, the monofilamentyarn composition then is typically suitable for all yarn types used inthe aforementioned industrial fabrics.

As a monofilament disclosed herein, it may be used as warp and/or weftyarns in the production of industrial fabrics such as paper machineclothing and engineered fabrics aforementioned, as the monofilament toproduce spiral links, as the pintles or pins for both on machine seamedfabrics, as a stuffer yarn in fabrics and spiral link belts (of a roundor polygonal cross section), as a binder yarn in some multilayer wovenfabrics, and as a yarn in a MD or CD yarn array. As a filament, it mayalso be further processed and cut into fiber used in batt material thatmay be attached to the base structure of some of these fabrics.

In certain embodiments, the mixture of polyester and silica glass beadcontent material provides the monofilament or fiber with improvedabrasion resistance. The above disclosed composition can also be used toproduce any of the other aforementioned components according to otherembodiments of the disclosure. These include fibers, filament yarns,films, foils, tapes, netting (mesh), rings, spiral link coils or otherextruded or spun elements, a structured deposit in a desired pattern, ora coating (either the deposit or coating can be continuous on a surface,or discontinuous in a desired pattern (for example rectangles), or sideby side continuous or discontinuous MD or CD strips; or continuous ordiscontinuous strips at an angle to the MD or CD, any/or of which may becurved, zigzag or sinusoidal, wherein the edges of the adjacent stripsare not in contact with each other, e.g., there is a “space” in betweenadjacent strips).

In embodiments of the inventive composition where the polyester is PET,water contact angle testing of PET monofilaments has shown that theaddition of silica glass beads to the PET resin during or before theextrusion process results in a higher water contact angle (74.7 degrees)when compared to a 100% (of the same PET) monofilament (contact angleonly 61-63 degrees). See FIG. 9. Typically, the water contact angle ofthe instant monofilament composition is greater than 74 degrees. Inparticular embodiments, the use of the silica glass bead additive worksin two ways: (1) it improves abrasion resistance (the desired outcome)and (2) it increases hydrophobicity.

In some embodiments, there may be additional additives in the mixture,such as stabilizers, compatibilizers, hydrolysis or oxidation-resistantadditives, dyes, and/or pigments. The polymeric material mixture is thenextruded or spun into fiber, yarn, rings, films, foils, mesh, netting,or other forms. The inventive material composition can also be used as astructured deposit or as a coating (either the deposit or coating can becontinuous on a surface, or discontinuous in a desired pattern (forexample, rectangles), or side by side continuous or discontinuous MD orCD strips wherein the edges of the adjacent strips are not in contactwith each other; e.g., there is a “space” in between adjacent strips) asa component of an industrial fabric or belt.

In the embodiments, the overall silica glass bead content in thecomponent is typically at least about 1%; or at least 1.34%; or at least2%; or at least 3%; or at least 4%; or greater than 4%.

In the embodiments, silica glass beads are typically less than 10microns in average particle size diameter.

In certain embodiments, silica glass beads are between 0.01-10 micronsin average particle size diameter. In additional embodiments, silicaglass beads are between 0.1-10 microns in average particle sizediameter. In further embodiments, silica glass beads are between 1-10microns in average particle size diameter.

Silica glass beads are glass beads comprising silica. Optionally, silicaglass beads also comprise metals, metal oxides, or other metalderivatives. A-glass (“A” for “alkali-lime”) is a silica glass that hasalkali metal oxide content (more than about 2.0%). E-glass (“E” forinitial electrical application) is a silica glass that is substantiallyalkali metal-free (less than about 2.0%). Other types of silica glassbeads include, but are not limited to, C-glass, R-glass, S-glass, andM-glass. See Matinlinna, J. P., Glass Fibers in Fiber-ReinforcedComposites, Handbook of Oral Biomaterials 264 (2014).

In some embodiments, the silica glass beads used in the compositions ofthe disclosure are either or both A-glass and E-glass beads. Inaddition, other types of silica glass beads may be added. In otherembodiments, the silica glass beads are both A-glass and E-glass silicabeads. In still other embodiments, silica glass beads are only A-glassbeads. In yet other embodiments, the silica glass beads are only E-glassbeads.

In an additional embodiment, the silica glass beads are embedded in apolymer carrier. In a certain embodiment, the silica glass beads areembedded in a PBT carrier.

In another embodiment, the combination of the polymer resin and silicaglass beads may be mixed with any suitable siloxane such as one or morepolysiloxanes.

In certain embodiments, the combination of the polymer resin and silicaglass beads may be mixed with a suitable fluoropolymer.

In a further embodiment, the aforementioned combination of materials areextruded or spun into various forms including, but not limited to,monofilaments, films, foils, meshes, nettings, sheets, etc.

In Another Embodiment, the Polymer Resins May be any Polyester, anyPolyamide, PEEK, PEK, PPS, Polyurethane, and/or Blends Thereof (e.g.,PET/PBT Blend and PET/PU Blend).

In another embodiment the silica glass beads are substantiallyspherical.

In some embodiments, the composition comprises 20%-98% of polymer resin.

In another embodiment, the composition to comprises 1%-5% of siloxane.

In yet another embodiment, the composition comprises 1%-4% silica glassbeads.

In a particular embodiment, the composition comprises:

(1) 2% silica glass beads;

(2) 2% siloxane;

(3) 6% PBT;

(4) 1% carbodiimide; and

(5) 89% PET

In another embodiment, the monofilament yarn has a round cross-section.In yet another embodiment, the monofilament yarn has a non-roundcross-section.

In another embodiment, the abrasion resistance of the monofilament yarnis improved at least 5% compared to said monofilament yarn made withoutsilica glass beads. In an additional embodiment, the abrasion resistanceof the monofilament yarn is improved at least 10% compared to saidmonofilament yarn made without silica glass beads. In a furtherembodiment, the abrasion resistance of the monofilament yarn is improvedat least 15% compared to said monofilament yarn made without silicaglass beads. In yet another embodiment, the abrasion resistance of themonofilament yarn is improved at least 20% compared to said monofilamentyarn made without silica glass beads.

The composition according to the present disclosure is also suitable forthe production of all the other aforementioned components that can beused in the manufacture of PMC; engineered fabrics used in a sludgefilter or other wet filtration process; base support structures forindustrial process belts, such as conveyor belts for industrial usessuch as food processing or mining; corrugator belts; spiral coil linksfor spiral link belts, their pintles or any stuffer yarns; or fabricsused in textile finishing processes, and a method of manufacturing thesame. Any of the above structures comprising yarns can be woven or notwoven, including spiral coil link structures as well as MD/CD yarnarrays. Further, the monofilament yarn compositions may be used asstuffers and pintles for both spiral link fabrics (stuffers) and allseams (e.g., pin seams, spiral, etc.).

For purposes of this disclosure, AIX-1390 is abrasion resistantmonofilament yarn made with A-glass silica particles and PET, AIX-1391is abrasion resistant monofilament yarn made with E-glass silicaparticles and PET, AIX-1394 is abrasion resistant monofilament yarn madewith E-glass silica particles and PET, AIX-1395 is abrasion resistantmonofilament yarn made with A-glass silica particles and polyamide.

The disclosure will now be described by the following non-limitingexamples:

TABLE 1 Properties of some monofilaments: Break 200 C. Tenacity Strain @3 Strain Shrink SAMPLE ID (gpd) gpd (%) (%) (%) 0.50 mm AIX-1390abrasion 4.6 10.1 23.3 8.2 resistant - “A” glass with siloxane and PET0.50 mm S-70 standard 4.8 9.9 24.0 7.5 product (100% PET) 0.85 mmAIX-1391 abrasion 4.2 6.7 14.8 21.0 resistant - “E” glass with siloxane,PET, and carbodiimide 0.85 mm HRS310 standard 4.7 5.7 15.1 24.0 PETproduct (has only carbodiimide)

PET monofilament samples were produced in a diameter of 0.20 mmcontaining 0%, 1%, 2%, and 3% micron-sized A-glass silica particles. Themonofilament physical properties and abrasion resistance of each sampleare below.

PET/Silica Physical Properties

100% PET 3% Silica 2% Silica 1% Silica (3844-61-1) (3844-61-3)(3844-62-3) (3844-62-4) 200 C. Shrink 12.5 12.85 12.9 12.8 (%) Tenacity(gpd) 6.518 5.696 5.817 6.174 Strain @ 2 gpd 2.30 2.60 2.56 2.47 (%)Break Strain 15.6 15.0 14.9 15.2 (%) Modulus (gpd) 108.2 102.1 102.8103.1(PBTXXX062813C1) Composition of A-Glass Concentrate Embedded in PBTCarrier with Siloxane:

Common Name Chemical Name or Formula Percent Polybutylene TerephthalatePolybutylene Terephthalate 60% Glass Oxide, A-Glass Beads SiO₂ 20%Siloxane Polydimethylsiloxane 20%(PBTXGB022113A1) Composition of A-Glass Concentrate Embedded in PBTCarrier:

Common Name Chemical Name or Formula Percent Polybutylene TerephthalatePolybutylene Terephthalate 70% Glass Oxide, A-Glass Beads SiO₂ 30%(PBTXGB090814A1) Composition of E-Glass Concentrate Embedded in PBTCarrier with Siloxane:

Common Name Chemical Name or Formula Percent Polybutylene TerephthalatePolybutylene Terephthalate 60% Glass Oxide, E-Glass Beads SiO₂ 20%Siloxane Polydimethylsiloxane 20%Abrasion Testing of Forming Fabric Samples

Three forming fabric samples were subjected to abrasion testing. Thesamples were marked Trial 1 J5076 S-32 PET 2200029, Trial 2 J5076PET/silica A-glass beads 3850-37.25 2200029, Trial 3 J5076 532/AIX-1368,PA6 (polyamide) 2210932 30378896-20 (alternating polyester andpolyamide). One Q13 (same as J5076 but has “Q13” code in final fabric)forming fabric standard style was also tested as a reference. PET is theyarn type for the code “J5076.” The Trial 1 monofilament was made as acontrol on the same day as the inventive monofilament, and was made onthe same extruder. The Trial 1 monofilament did not contain silica glassbead additive. The Trial 2 monofilament sample J5076 PET/Silica3850-37.25 2200029 contained 2% A-glass beads and 2% siloxane. The Trial3 monofilament did not contain silica glass bead additive.

Test Method

Two pieces of each sample were tested in a forming fabric abrasiontester. One Q13 forming fabric standard style was also run to comparewith the test samples. In this tester, the forming fabric sample iswrapped over a rotating roll with a ceramic coating and is loaded undertension in the machine direction with 8 kN/m. Water containing 1.0% (250g) of the filler is sprayed over the sample. The running time to fabricfailure due to breaking/tearing was measured. The filler used wascalcium carbonate (chalk, GCC) called Sjöhästen FF.

Results

Running time (min) to tear (FIG. 10)

Samples number Running time (min) Trial 1 2200029 35 and 35 Trial 22200029 61 and 67 Trial 3 2210932 67 and 68 Q13 our standard 46 and 51

Each test was run until the sample tore and then the filler solution wasreplaced. Two pieces of each sample were run. Trial 2 is an inventivefabric according to an embodiment of the disclosure. Trial 1 is acontrol sample and Trial 3 is made of polyamide of the same size as theother two trials. The silica used in these trials was A-Glass. Trial 2sample J5076 PET/Silica 3850-37.25 2200029 was processed into amonofilament using a blend of 0.95 IV PET resin (90%) and the A-glassbead/siloxane additive from Foster Corp. (PBTXXX062813C1) at 10%.

Micron-sized silica (<10 microns) (A-glass) beads and siloxane wereadded to PET resin via the addition of a PBT/silica/siloxane concentratefrom Foster Corporation (PBTXXX062813C1) into the polymer melt duringthe monofilament extrusion process.

From this test, it appears that the other monofilament physicalproperties are not significantly changed when 1%, 2%, or 3% of themicron-sized A-glass beads are blended into the PET monofilament. SeeTable 1. The abrasion resistance of the fabrics comprising the inventivePET monofilament with the 2 and 3% level A-glass beads is improved byabout 20% compared to a fabric comprising 100% PET monofilament. SeeFIG. 1. This is a significant improvement in fabric abrasion resistanceand brings the abrasion resistance closer to fabrics woven withpolyamide CD monofilaments without sacrificing the high CD dimensionalstability (tensile) and low moisture uptake properties of polyestermonofilaments. But hydrolysis resistance testing of a 0.85 mmPET/A-glass monofilament shows inadequate hydrolysis resistance for usein the dryer section of a paper machine. See FIG. 5.

Micron-sized silica (<10 microns) (A-glass) beads were also added to PETmonofilaments via the addition of a PBT/silica concentrate from FosterCorporation (PBTXGB022113A1) into the polymer melt before or during theextrusion process.

Further testing of different silica concentrates from Foster Corporationshowed that the use of a specific type of silica called “E-glass” in PETmonofilaments exhibits improved monofilament abrasion along withadequate hydrolysis resistance, allowing the use of PET monofilamentsloaded with “E-glass” beads in fabric applications where hydrolysisresistance is not needed (e.g., forming section of a paper machine) orin applications where hydrolysis resistance is needed (e.g., dryersection of a paper machine). “A-glass” beads may also be used inapplications where hydrolysis resistance is not needed. See FIG. 6.

Further to improving the abrasion resistance as well as improvingfrictional properties (reducing fabric drag over stationary elements andsubsequent drive load) on the machine parts, a polymer blend was createdthat has silica glass beads and high molecular weight siloxane. Byadding siloxane, the frictional properties of the monofilament yarn alsoimproved. The siloxane added in the additive compound was GenioplastPellet “S” from Wacker, but any other high molecular weight siloxane canbe added.

The composition of the masterbatch that has silica in the form of A orE-glass beads and siloxane can be:

(1) Silica (A or E-glass): 1-30%;

(2) High Mol. Wt. Siloxane: 0-4%; and

(3) Polybutylene Terephthalate Resin: 20-98%

(NOTE, the masterbatch is then added to the PET resin during extrusion)

These silica glass beads can be round or spherical in shape. This kindof masterbatch concentrate can be used with all thermoplastics,including but not limited to, e.g., polyamides (Nylon 6, Nylon 6,6,Nylon 6,10, Nylon 6,12, etc.), polyesters (PBT, PET, PEN, PTI, etc.),copolyesters like THERMX®, HYTREL®, ARNITEL®, etc., and high meltingtemperature polymers like PPS, PEEK, polyurethanes, etc.

These kinds of monofilaments (or other component form) can be used inany application where better, improved abrasion resistance is needed.This will reduce the wear of the industrial fabrics and belts andimprove their longevity and performance. The abrasion/wear tests showedat least 30-40% improvement in the life of the fabric both in terms ofcaliper (thickness) and weight loss. See FIGS. 7 and 11.

Hydrolysis testing of silica-loaded products has shown that specifictypes of silica glass beads will be preferred so that use in PETmonofilaments to be exposed to high temperature steam is viable.Hydrolysis testing results are reported from monofilaments each loadedwith a different type of silica bead (E-glass or A-glass) at 1.34% and2.0% loading along with an additive to prevent hydrolysis and a siloxaneadditive to reduce the coefficient of friction. See FIGS. 5, 6, and 8.

The results again show that PET monofilament loaded with A-glass beads(3850-50-3 and 4) has no positive affect on the hydrolysis resistance ofthe monofilament. Samples 3850-50-1 and 2 are loaded with E-glass beads.The hydrolysis resistance of samples 3850-50-1 and 2 (E-glass beads) areshown to be equivalent to a PET control monofilament suitable for use ina high temperature steam environment such as the dryer section of apaper making machine.

Sample Compositions:

-   -   3850-50-1: 1.34% E-glass/2% siloxane/1.25% carbodiimide in 0.72        IV (Intrinsic Viscosity) PET    -   3850-50-2: 2% E-glass/2% siloxane/1.25% carbodiimide in 0.72 IV        PET    -   3850-50-3: 2% A-glass/2% siloxane/1.25% carbodiimide in 0.72 IV        PET    -   3850-50-4: 1.34% A-glass/2% siloxane/1.25% carbodiimide in 0.72        IV PET

The monofilament abrasion resistance of PET monofilament loaded withE-glass type silica was found to be better than the Einlehner abrasionresistance of the 100% PET control monofilament. See, e.g., FIGS. 1, 7,and 8.

SEM images (showing a paper side view and a cross section view) ofmonofilament yarns containing E-glass beads indicate the distribution ofE-glass beads within the monofilament yarn. See FIG. 2.

A stress versus strain plot of two monofilaments, the inventive 0.85 mmAIX-1391 (with E-glass beads) versus a 0.85 mm HRS310 polyester(HR=Hydrolysis Resistant), indicates that the two monofilaments havesimilar stress/strain properties. See FIG. 3.

A stress versus strain plot of the inventive 0.50 mm AIX-1390 (withA-glass beads) monofilament versus a standard 0.50 mm S-70 monofilamentindicates that the two monofilaments also have very similar tensileproperties. See FIG. 4.

The percent loss of weight and caliper (thickness) of a regular standard0.85 mm PET monofilament was higher (worse) than a Hi-Life PETmonofilament, which is the inventive abrasion resistant PET. See FIG.11.

It took more time to break PET fabrics made with yarns comprising 2.0%A-glass beads (AIX-1384) than a PET reference material (HCR 280), aHYTREL® reference material (AIX-1382), and HYTREL® with 2.0% A-glassbeads (AIX-1383). Note however, the inventive HYTREL® materialcomposition was better than the standard HYTREL® as well. See FIG. 12.The monofilaments were 0.50 mm round cross sections.

An image showing a fabric woven with alternating monofilament yarns(across the image) of composition S1618 0.50 mm S70 PET and 100% PA6indicates abrasion resistance after 1 hour of external wear. See FIG.13.

An image showing the wear of the fabric in FIG. 13 indicates abrasionresistance after 2 hours of external wear. See FIG. 14.

An image showing a fabric woven like that of FIG. 13, but the S70 PETmonofilament was replaced by one with a composition S1618 0.50 mmAIX-1390 (the inventive yarn composition with A-glass beads) indicatesabrasion resistance after 1 hour of external wear. See FIG. 15.

An image showing the fabric of FIG. 15 indicates abrasion resistanceafter 2 hours of external wear. See FIG. 16.

Thus the main features of this material composition are:

1. Very good abrasion resistance. The actual fabrics tested comprisingthe inventive monofilaments demonstrated at least 20% improvement inabrasion resistance.

2. Minimal impact on the other physical properties of the resincomponent.

3. E-glass beads having a positive impact on the hydrolysis resistanceof the resin component.

While specific embodiments of the disclosure have been discussed, theabove specification is illustrative and not restrictive. One of ordinaryskill in the art will appreciate that numerous changes and modificationscan be made to the disclosure, and that such changes and modificationscan be made without departing from the spirit and scope of thedisclosure. The full scope of the disclosure should be determined byreference to the claims, along with their full scope of equivalents, andthe specification, along with such variations.

Likewise, although technical features of the present invention mighthave been described only with respect to certain embodiments, theordinarily skilled artisan will understand that features of someembodiments may be combined with features of other embodiments and thatspecific combinations of features described with respect to certainembodiments may also be combined with other features or other specificcombinations of features described with respect to other embodiments.

Each patent, patent application, and publication cited or described inthe present application is hereby incorporated by reference in itsentirety as if each individual patent, patent application, orpublication was specifically and individually indicated to beincorporated by reference.

What is claimed is:
 1. A method of manufacturing a resin componentcomposition comprising a polymer resin and silica glass beads, whereinsaid silica glass beads are added simultaneously to said polymer resin,which is then extruded or spun, wherein the silica glass beads areselected from A-glass and E-glass beads, and the silica glass beads areless than 10 microns and greater than or equal to 0.01 microns inaverage particle size diameter, and wherein at least about 1% and nomore than 4% of said composition by weight comprises the silica glassbeads.
 2. A method of manufacturing a resin component compositionaccording to claim 1, further comprising siloxane additive, wherein asiloxane additive and said silica glass beads are added simultaneouslyto said polymer resin, which is then extruded or spun.
 3. A method ofmanufacturing the composition according to claim 1, comprising one ormore polymers selected from the group consisting of: polyethylenenaphthalate (PEN), polyethylene terephthalate (PET), polybutylenenaphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), polybutyleneterephthalate (PBT), polyamide (PA 6, PA 6,6, PA 6,12, PA 6,10, PA 4,6,PA 10, PA 11, PA 12; MXD6, and aromatic derivatives thereof), polyetherether ketone (PEEK), polyether ketone (PEK), poly(p-phenylene sulfide)(PPS/RYTON®), polyurethane, polysiloxane, and copolymers thereof.
 4. Amethod of manufacturing the composition according to claim 3, comprisingtwo or more polymers selected from the group consisting of: polyethylenenaphthalate (PEN), polyethylene terephthalate (PET), polybutylenenaphthalate (PBN), polytrimethylene naphthalate (PTN),poly(cyclohexylene dimethylene terephthalate) acid (PCTA), andpolybutylene terephthalate (PBT).
 5. A method of manufacturing thecomposition according to claim 3, comprising at least two polymerresins, wherein said silica glass beads are added simultaneously to saidpolymer resins, which are then extruded or spun.
 6. A method ofmanufacturing a resin component composition according to claim 5,further comprising a siloxane additive, wherein the siloxane additiveand said silica glass beads are added simultaneously to said polymerresins, which are then extruded or spun.
 7. A method of manufacturingthe composition according to claim 6, comprising two or more polymersselected from the group consisting of: polyethylene naphthalate (PEN),polyethylene terephthalate (PET), polybutylene naphthalate (PBN),polytrimethylene naphthalate (PTN), poly(cyclohexylene dimethyleneterephthalate) acid (PCTA), polybutylene terephthalate (PBT), polyamide(PA 6, PA 6,6, PA 6,12, PA 6,10, PA 4,6, PA 10, PA 11, PA 12; MXD6, andaromatic derivatives thereof), polyether ether ketone (PEEK), polyetherketone (PEK), poly(p-phenylene sulfide) (PPS/RYTON®), polyurethane,polysiloxane, and copolymers thereof.
 8. A method of manufacturing thecomposition according to claim 7, comprising two or more polymersselected from the group consisting of: polyethylene naphthalate (PEN),polyethylene terephthalate (PET), polybutylene naphthalate (PBN),polytrimethylene naphthalate (PTN), poly(cyclohexylene dimethyleneterephthalate) acid (PCTA), and polybutylene terephthalate (PBT).
 9. Amethod of manufacturing the composition according to claim 1, whereinsaid composition comprises one or more additives selected from the groupconsisting of: stabilizers, compatibilizers, hydrolysis oroxidation-resistant additives, dyes, and pigments.
 10. A method ofmanufacturing the composition according to claim 1, wherein saidcomposition is extruded or spun into a component selected from the groupconsisting of fiber, yarn, rings, films, foil, tape, mesh, spiral linkcoil and netting; or is a structured deposit or coating.
 11. A method ofmanufacturing the composition according to claim 1, wherein about 4% toabout 98% of said composition by weight comprises the polymer resin. 12.A method of manufacturing the composition according to claim 11, whereinabout 0.5% to about 5% of said composition by weight comprises asiloxane additive.
 13. A method of manufacturing the compositionaccording to claim 12, wherein about 1% to about 5% of said compositionby weight comprises the siloxane additive.
 14. A method of manufacturingthe composition according to claim 11, wherein the composition comprisesthe polymer resin in an amount of about 20% to about 98% of saidcomposition by weight.
 15. A method of manufacturing the compositionaccording to claim 14, wherein: (a) 89% of said composition by weight isPET; (b) 6% of said composition by weight is PBT; (c) 2% of saidcomposition by weight is a siloxane additive; (d) 1% of said compositionby weight is carbodiimide; and (e) 2% of said composition by weight isthe silica glass beads.